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Eureka! Industrial Energy Technology Innovation
Tuesday, May 16 9:30-10:45 am
Panelists
George Andraos, Ford & Michael Schratz, Dialight
Brian Myers, Toyota Steve Schultz, 3M Eli Levine, U.S. Department of Energy
(Moderator)
2
Better Buildings Summit Industrial Energy Technology/
Emerging Technologies in Manufacturing
Presenters: George Andraos – Ford Motor Co, Director of Energy Michael Schratz – Dialight, VP of Sales and Marketing
SLIDE 5
Sustainability at Ford
Thursday, May 18, 2017
Social
Sustainable “ A business that makes nothing but
money is a poor business.”
- Henry Ford
“Improved sustainable performance is not just a
requirement, but a tremendous business
opportunity.” - Bill Ford
Meeting The Needs Of The Present Without Compromising The Future
DOE Better Buildings Summit
SLIDE 6
Sustainability through LED Lighting
Thursday, May 18, 2017
Using this process, Ford has replaced 30% of HID lamps in the US compared to industrial industry at 3% inefficient lighting conversion
Identify lighting need
Interview suppliers
Technical product
evaluation
Technology roadmap
Add products to
Ford’s Lighting
QPL
Negotiate pricing
Lighting Specification
Process
DOE Better Buildings Summit
SLIDE 7
Ford Supplier Partnerships
Thursday, May 18, 2017
•Key Partners: Cree, Hubbell and Acuity
•Partner: Dialight • Initiated by a small LED trial in Livonia area facility in 2012
•Global LED High Bay specification process concluded in 2013
•Currently 75,000 fixtures installed across 7 countries & 51 facilities
DOE Better Buildings Summit
High Bay Applications
Other Applications
SLIDE 8
LED Project Challenges and Lessons Learned
Thursday, May 18, 2017 DOE Better Buildings Summit
LED Challenges & Lessons
Learned
Standardization
Financials
Shadowing
Darker Ceiling
Perception
LED = directional light source
Product & process
Reaching payback and total cost of ownership goals
Due to less up-light
Changing the mindset
SLIDE 9
75,000 Fixtures Globally
22 MW demand reduction
= Large Assembly Plant Demand
Sustainability Impacts
Thursday, May 18, 2017
75,000 metric tons of CO2
DOE Better Buildings Summit
High Bay Applications
Annual CO2 Reduction
SLIDE 10
Improved plant environment
Sustainability and Technology Impacts (Non-Energy)
Thursday, May 18, 2017
100,000+ maintenance hours
DOE Better Buildings Summit
Annual Maintenance Savings Improved Light Levels & Uniformity
SLIDE 11
• Reduce power, extend lifetime
• Reduce part count from 261 to 21 parts
• Streamlined manufacturing and lead time
• Reduce installation time
Sustainability and Technology Impacts (Non-Energy)
Thursday, May 18, 2017
• Tactical logistics w/ 3 channel partners
• Reusable packaging eliminates
cardboard
• Reducing # of trucks for transporting
DOE Better Buildings Summit
Simplified Logistics Next Generation Technology
SLIDE 12
Next Generation Technology
Thursday, May 18, 2017
Tridium BMS
Wirelessly controls enabled lights connected to building management system (BMS)
802.15.4 2.4GHz Wireless
Light
Light
Light Gateway 1
• Energy conservation/management
• Equipment & space utilization
• Inventory management
• Predictive maintenance
• Human convenience
• Emergency notification and management
• Integrated facility security
• Human centric light – right light at the
right time
• Adaptive lighting – measurement &
adjustment
DOE Better Buildings Summit
Productivity Safety & Security
As energy efficient LED lighting becomes more prevalent in industrial plants, the next step for significant reduction in energy and operating cost will be
realized through intelligent control systems
PROTECTED 関係者外秘
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Energy Project on Existing Automotive Paint Shop Equipment
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PROTECTED 関係者外秘
TOYOTA North America
Corolla
Venza Tacoma
Highlander Highlander Hybrid
RAV4
Sienna Tundra
Sequoia
Lexus RX 350/450h
Camry Camry Hybrid
Avalon Avalon Hybrid
Lexus ES 350
PROTECTED 関係者外秘
TABC 1971
CAPTIN 1985
TMMK 1988
TMMC 1988
BODINE 1990
TEMA 1996 TMMWV
1998 TMMI 1999
TMMAL 2003 TMMBC
2004
TMMTX 2006
SIA 2007
TMMC 2 2008
BODINE 2005
TMMMS 2011
Headquarters Plano, PE Georgetown
Component (5) Vehicle Assembly (8)
Engine Assembly (3) R&D (4)
TMNA 29M Sq FT
TMMMS
Commitment To North America
PROTECTED 関係者外秘
TMNA Energy Team Background
1996 - Program starts, TMNA was born 1997 - Focus on Facilities Control areas:
Lighting, HVAC, Boilers, ACUs, Chillers, etc. 2001- Set 5 year plan Began focus on process Year one results were 21% reduction 2002- Reset and restarted 5 Year Plan for Energy 2003- EPA initiated Industrial Round Table 2004- Toyota joins Energy Star Toyota Leads formation of Automotive Vehicle Focus Group 2004- Toyota wins it first Energy Star Partner of the Year Award 2016- Toyota wins 12th consecutive Energy Star Partner of the Year Award
PROTECTED 関係者外秘
Background
1. Paint process is >50% of overall plant energy consumption
2. Part of the Energy Reduction Plan is elimination of the Central Steam Plant
3. Air Supply Houses (ASH) were designed to utilize steam to control paint booth temperature and humidity
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PROTECTED 関係者外秘
Project Identification
1. Introduced in at an automotive competitor
2. Adiabatic humidification is RO or DI water sprayed into the supply air stream to control paint booth humidity
3. Retrofit the existing ASH humidity control systems in order eliminate steam
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PROTECTED 関係者外秘
Air Supply House Wet wall, Steam injection
Wet WallSteam Injection
Chilled WaterSteam Reheat
Outside AirPre-Heat
72’F/72% RH
To Paint Booth
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PROTECTED 関係者外秘
Winter Operation
Outside Air
1
2
3
4
6
Winter SP
Pre-heat Burner
Wet Wall
Dri-Steem
Reheat
Dry Bulb Temperature - ºF
M o
i s t
u r e
–
g r
a i n
s /
l b
Wet Wall
Design Concept High Pressure Spray
Outside Air
1 Pre - heat Burner
2
Winter SP 6
3
Dry Bulb Temperature - ºF
M o
i s
t u r
e –
g
r a i
n s
/ l
b
21
PROTECTED 関係者外秘
Outside AirPre-Heat
(Wet Wall and Steam ELIMINATED)
Chilled Water MINIMIZEDSteam Reheat MINIMIZED
HIGH PRESSURE SPRAY
Redesigned Air Supply House HIGH PRESSURE SPRAY HUMIDIFICATION
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72’F/72% RH
To Paint Booth
PROTECTED 関係者外秘
Pilot Energy Savings
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0
10000
20000
30000
40000
50000
60000
70000
Previous Carel system
NG
(M
Mbt
u/ye
ar)
NG
(Steam)
NG
(Preheat)
NG
(For steam)
NG
(Preheat)
0
10k
20k
30k
40k
50k
60k
70k
Previous HPH
Nat
Gas
(M
Mbt
u/ye
ar)
Reheat
Preheat
Steam
Preheat
23,000 MMbtu/year
0
200000
400000
600000
800000
1000000
1200000
1400000
1600000
Previous Carel system
Ele
ctr
icity
(kW
h) Electricity
(Supply fan) Electricity
(Supply fan)
0
200k
400k
600k
800k
1000k
1200k
1400k
1600k
Previous HPH
Ele
ctr
icity
(kW
h)/
year
37,000 kWh/year
Supply fan Supply
fan
Natural Gas Electricity
PROTECTED 関係者外秘
1. Set pumps,
piping. 2. Install high
pressure spray 3. Remove wet wall
media 4. Abandon steam
injection header
Implementation
24
PROTECTED 関係者外秘
25
1.Preheat burner tuning
2.Adjustment to program timing
3.Reduction of spray nozzles
Challenges Issue: Unstable operation during spring & fall seasons –countermeasures -
PROTECTED 関係者外秘
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1.Certified weld inspection on all HP welds
2.Resized HP discharge hoses 3.Relocated pulse dampeners 4. Installed additional piping
supports
Challenges Issue: HP piping failures countermeasures -
PROTECTED 関係者外秘
RO
TAN
K
ASH
5 units 867,000cfm
Pump & controls
EAST PAINT WEST PAINT
RO
TAN
K
ASH
8 units 1,030,000cfm
Pump & controls
TAN
K
TAN
K
TAN
K
ED Pretreatment
23Kgal 23Kgal 15Kgal 15Kgal
ED Pretreatment
Modify transfer pipe
125gpm, 15Kgal 2x125gpm
Challenges
Increase capacities, storage. Get RO to the HPH Issue: RO water for HPH
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PROTECTED 関係者外秘
1. Full project Nov 2013 – 2017 2. M&V data collected during cold weather 3. Projected project savings based on the pilot savings.
a) ## MMBtus b) $##M
4. No effect on paint quality. 5. Steam boiler demand reduced
Overall Impact
29 25000
35000
45000
55000
65000
75000
85000
Current E Humd E Reheat W Humd W Reheat Plas Humd Plas Reheat Result
Dem
and
TEMA TMMI PJ Steam Reductions
PROTECTED 関係者外秘
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Additional benefits: 1. Increased ASH control capacity and built in trending
functions 2. Reduced steam piping maintenance 3. Reduced static pressure with wet wall removed, lower fan
speed
Reflections: a. Do an in-depth health assessment of existing equipment. b. Know the metering capabilities. c. Get to know the shop personnel and get them involved.
Summary
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Increasing Energy Cost$
Engages our TM’s CO2 Reduction
Benefits Society
Great
Target Setting
Good Management
Benefits of Better Plants Participation
36 18 May 2017 . All Rights Reserved. © 3M
Enhanced Communications Energy Monitoring Shutdown Kaizens (Treasure Hunts) Immersion Cooling
Industrial Energy Technology Innovations
37 . All Rights Reserved. 18 May 2017 © 3M
Driving Progress Around the World
Mexico
Brazil
Colombia
Venezuela
Argentina
Chile
Costa Rica
Italy
France
UK
Turkey
Canada
Poland
Germany
Russia
Japan
China
Taiwan
Vietnam Thailand
Singapore
Indonesia
Hong Kong
Korea
Philippines
India
UAE
Malaysia
South Africa Belgium
Spain
Netherlands
Switzerland
Sweden
New Zealand
Australia
$30 Billion Sales 60% International
5 Business Groups, 26 Business Units
Operations in 29 States and 70 Countries
Sales in 200 Countries
89,000 + Employees
38 18 May 2017 . All Rights Reserved. © 3M
Monthly Energy Web Conferences Help Keep our Network of Energy Champions Informed and Engaged
39 18 May 2017 . All Rights Reserved. © 3M
Monthly Energy Web Conferences Provide an Opportunity to Remind People of Important Tasks
41 18 May 2017 . All Rights Reserved. © 3M
Our Corporate Energy Management Website Provides Access to Important Resources for our Energy Practitioners
42 18 May 2017 . All Rights Reserved. © 3M
Our Corporate Energy Management SharePoint Site Provides a Convenient Location for Documents People Need to do Their Job
43 . All Rights Reserved. 18 May 2017 © 3M 3M Confidential. 43 . All Rights Reserved. 18 May 2017 © 3M 3M Confidential.
Output (Rate in yds per hour, lbs per hour…)
Work (Rate of energy consumption)
Time Series Visualization Energy Monitoring
Energy = Integration of work function (BTU, KW-hr)
Output = Integration of rate function
Segmented by Product, Order, Run, Batch
Export to excel for analysis
44 . All Rights Reserved. 18 May 2017 © 3M 3M Confidential. 44 . All Rights Reserved. 18 May 2017 © 3M 3M Confidential.
Why Energy Monitoring?
What you don’t measure, you can’t control - Make energy visible
Metering:
• Sub-metering
• Energy Map - Identify where energy is used and how much it costs
Targeting:
• Establish energy baselines
• Establish energy targets normalized for product types, outside weather conditions and any other related variables
• Provide real-time energy information for operating personnel
• Provide energy consumption reporting for management for tracking and budgeting
Why Energy Monitoring?
45 . All Rights Reserved. 18 May 2017 © 3M 3M Confidential. 45 . All Rights Reserved. 18 May 2017 © 3M 3M Confidential.
3M Engineering Standards Require Meters to be Installed for Energy Flows Greater than Specific Thresholds
Why Energy Monitoring?
Utility
Suggested Threshold
Unit Convert UnitHours/ yr Units/ yr
Recommended Meter Type (3M Mech Standing
Spec sec 15980) Comments
Power 100 KW 100 KW 4,000 400,000 varies
Utilize integral meter at drives, substation breakers, etc where possible
Compressed Air 100 CFM 6,000 CFH 4,000 24,000,000 Thermal dispersionSteam 1000 #/hr 1,000 #/hr 4,000 4,000,000 Vortex shedding
Chilled Water 50 tons 50 ton hr 4,000 200,000 UltrasonicMagnetic Flow meter can be used for piping 4" and below
Natural Gas 400 MBH 400 CFH 4,000 1,600,000 Thermal dispersion
Fuel Oil 400 MBH 3 gph 4,000 11,440 UltrasonicMagnetic Flow meter can be used for piping 4" and below
Nitrogen 20 CFM 1,200 CFH 4,000 4,800,000 Thermal dispersion
Water 50 GPM 3,000 gph 4,000 12,000,000 UltrasonicMagnetic Flow meter can be used for piping 4" and below
46 . All Rights Reserved. 18 May 2017 © 3M 3M Confidential. 46 . All Rights Reserved. 18 May 2017 © 3M 3M Confidential.
The Bridge from Metering to Monitoring … Why Energy Monitoring?
… then on to Contextualization and Intelligent Systems
47 . All Rights Reserved. 18 May 2017 © 3M
Treasure Hunt/Shutdown Kaizens (Treasure Hunts)
Present at department engineering meeting and operator crew meetings to communicate the initiative and get everyone’s buy-in
Recruit maintenance supervisors to help with technical details and to help drive job work orders to completion
Divide the factory into smaller more manageable work center areas Start where we have the most influence and authority Complete two walk-throughs of the area looking for savings
opportunities – First, after hours when all the equipment should be off, and then – With the Process Engineer to get their ideas, buy in, and support
Plan of Attack
48
Treasure Hunt/Shutdown Kaizens (Treasure Hunts)
Estimate the savings and costs before the event ends Obtain commitment to pursue implementation Avoid high cost engineering studies and consultants Implement with plant resources whenever possible Track and REPORT the savings
Low and No Cost Opportunities Exist – Quantify the Savings
Opportunity RecommendationAnnual
Savings $Implementation
Cost $Payback(years)
LO Heaters Shut LO heaters off when production is down $6,000 $0 0Penthouse 3 & 4 Lighting Add timers $3,000 $400 0.13House Vacuum System Add start/stop controls at location $12,000 $3,000 0.25Converting Fan Reduction Lockout 10 of 36 fans $24,000 $0 0Converting Split Recycle System Shut down split recycler when not running by adding local controls $60,000 $12,000 0.20City Water Waste Add closed loop system $20,000 $22,000 1.10Return Product Sill Bearings Eliminate compressed air to product sill bearings $24,000 $2,200 0.09
Total $149,000 $39,600 0.27
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Treasure Hunt/Shutdown Kaizens (Treasure Hunts) • Automate and Educate • Require auto shutdown on new equipment • Connect to building automation whenever possible • Schedule Kaizen event with each department and develop shutdown
procedures
• Verification checks • Baseline Energy
• Complete on shutdowns • Verify annually
50 50 . All Rights Reserved. 18 May 2017 © 3M 3M Confidential.
Immersion Cooling 3M™ Novec™ Engineered Fluids The Novec Engineered Fluids based on safe and sustainable chemistry to replace PFC’s. Novec is used in a wide range of applications from thermal management to precision cleaning. The media are colorless, odorless, electrically non-conductive and non-flammable
• Wide range of boiling
• Electrically insulating
• Non-corrosive
• Non-flammable
• Good compatibility with many materials
• Low Global warming potential (GWP)
• No ozone depletion potential (ODP)
• Low odor
Features and Benefits
51
Why Server Immersion Cooling? Efficiency:
• Data centers consume 2% of the world energy • 38% of data center energy is used for cooling
Performance: • Higher server packaging density and processor
clock rate are both thermally limited
Traditional Cooling Tradeoffs:
Air Cooling
Water Cooling
Energy Efficient
High Density
Complex
Expensive
Direct immersion of electrical components with no damage or impact on performance
Higher heat transfer efficiency through direct contact phase change at heat generating components for best possible energy efficiency (1.01 pPUE) and processor performance
Reduce thermal management as design constraint and thermal management hardware at server, rack and facility level for simplicity and cost reduction
Increased packaging density for lower latency and increased communication bandwidth
Solution
https://www.youtube.com/watch?feature=player_detailpage&v=uV7MDhqNyXE#t=28
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Technology Vision Demonstrated 40MW Immersion Cooled Data Center
250KW Tank
Data Center Building. All Operations on 2nd floor Dry Cooling Towers Key Metrics: 250KW per tank
pPUE ~1.01 3230 watts per square foot
<3 liters per KW ASIC-based processors
Low facility construction cost
Tank Inside View During Operation